Equipment Pre-Startup And Startup Checklist; Pre-Startup; Startup - York YCAL Series Installation Operation & Maintenance

FORM 150.66-NM3
ISSUE DATE: 09/25/2020

EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST

JOB NAME: ______________________________
SALES ORDER #: _________________________
LOCATION: ______________________________
SOLD BY: ________________________________
INSTALLING
CONTRACTOR: ___________________________
START-UP
TECHNICIAN/
COMPANY: _______________________________
START‑UP DATE : _________________________
CHILLER MODEL #: _______________________
SERIAL #: ______________________________

Pre-Startup

Checking the System
Prior To Initial Start (No Power)
Unit Checks
 1. Inspect the unit for shipping or installation dam-
age.
 2. Ensure that all piping has been completed.
 3. Visually check for refrigerant piping leaks.
 4. Open suction line ball valve, discharge line ball
valve, and liquid line valve for each system.
 5. The compressor oil level should be maintained so
that an oil level is visible in the sight glass. The oil
level can only be tested when the compressor is
running in stabilized conditions, guaranteeing that
there is no liquid refrigerant in the lower shell of
the compressor. When running, the oil should be
in the bottom half of the sight glass. At shutdown,
the oil level should also be visible in the bottom
half of the oil sight glass.
 6. Ensure that water pumps are on. Check and adjust
water pump flow rate and pressure drop across
the cooler (see OPERATIONAL LIMITATIONS).
Verify flow switch operation.
Excessive flow may cause catastrophic
damage to the evaporator.
JOHNSON CONTROLS
 7. Check the control panel to ensure it is free of
foreign material (wires, metal chips, or similar
materials).
 8. Visually inspect wiring (power and control). Wir-
ing MUST meet N.E.C. and local codes.
 9. Check tightness of power wiring inside the power
panel on both sides of the motor contactors and
overloads.
 10. Check for proper size fuses in main and control
circuits, and verify overload setting corresponds
with RLA and FLA values in electrical tables.
 11. Ensure that 120 VAC Control Power to TB1 has
15 A minimum capacity.
 12. Be certain all water temperature sensors are in-
serted completely in their respective wells and are
coated with heat conductive compound.
 13. Ensure that evaporator TXV bulbs are strapped
onto the suction lines at 4 or 8 o'clock positions
or suction temp. sensors if EEVs are installed.
Compressor Heaters
(Power ON – 24 Hours Before Start)
 1. Apply 120 VAC and verify its value between
terminals 5 and 2 of CTB2. The voltage should
be 120 VAC plus or minus 10%.
Power must be applied 24 hours before start-up.
Each heater should draw approximately 0.5 A to
1 A.

Startup

Panel Checks
(Power ON – Both Unit Switches OFF)
 1. Apply 3-phase power and verify its value. Volt-
age imbalance should be no more than 2% of the
average voltage.
 2. Apply 120 VAC and verify its value on the ter-
minal block in the Power Panel. Make the mea-
surement between terminals 5 and 2 of TB1. The
voltage should be 120 VAC plus or minus 10%.
 3. Program/verify the Cooling Setpoints, Program
Setpoints, and unit Options. Record the values
below (see SECTION 7 - UNIT CONTROLS for
programming instruction) in Table 1.
 4. Put the unit into Service Mode (as described in
SECTION 9 - SERVICE AND TROUBLESHOOT-
ING) and cycle each condenser fan to ensure
proper rotation.
SECTION 5 - COMMISSIONING
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